1986 Dodge W100 Service Manual

The 1986 Dodge W100 Service Manual provides comprehensive technical information for maintaining and repairing the Dodge W100 pickup truck. This manual covers engine specifications, transmission systems, electrical systems, braking systems, suspension, steering, and routine maintenance procedures for the 1986 model year. Below are key sections for specifications, maintenance, troubleshooting, and repair procedures.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Transmission & Drivetrain 5. Electrical Systems 6. Braking System 7. Suspension & Steering 8. Fuel System 9. Cooling System 10. Troubleshooting Guide 11. Safety Precautions

Vehicle Specifications

Key specifications for the 1986 Dodge W100 pickup truck including engine options, dimensions, and capacities.

Specification	Description
Engine Options	3.7L Slant-6, 5.2L V8, 5.9L V8
Transmission	4-speed manual, 3-speed automatic
Wheelbase	115 inches
Payload Capacity	1,500 lbs
Fuel Capacity	20 gallons
Gross Vehicle Weight	5,200 lbs
Braking System	Front disc, rear drum
Suspension	Front independent, rear leaf spring
Steering	Power-assisted recirculating ball
Electrical System	12-volt negative ground

Maintenance Schedule

Recommended maintenance intervals for optimal vehicle performance and longevity.

Oil Change: Every 3,000 miles or 3 months
Air Filter: Every 12,000 miles
Spark Plugs: Every 30,000 miles
Coolant Flush: Every 30,000 miles or 2 years
Transmission Fluid: Every 15,000 miles
Brake Fluid: Every 24,000 miles or 2 years
Timing Belt: Every 60,000 miles

WARNING! Always use recommended fluids and follow torque specifications. Failure to maintain proper intervals may void warranty.

Engine Systems

Detailed information on engine components, specifications, and service procedures.

Engine Identification: Located on passenger side cylinder block
Compression Ratio: 8.4:1 (5.2L V8)
Firing Order: 1-8-4-3-6-5-7-2 (V8 engines)
Oil Pressure: 30-60 psi at 2000 RPM
Ignition Timing: 10° BTDC at idle
Valve Clearance: 0.015" intake, 0.025" exhaust (hot)

CAUTION! Always disconnect battery before working on electrical systems. Allow engine to cool before performing maintenance.

Transmission & Drivetrain

Service procedures for manual and automatic transmissions, transfer case, and differential.

Manual Transmission: Check fluid level at fill plug
Automatic Transmission: Use Dexron II/Mercon fluid
Transfer Case: Lubricate every 15,000 miles
Differential: Check gear oil level monthly
U-Joints: Lubricate every 6,000 miles

Tip: Always use jack stands when working underneath vehicle. Never rely solely on hydraulic jack.

Electrical Systems

Wiring diagrams, component locations, and troubleshooting procedures.

Component	Specification
Battery	12V, 60Ah minimum
Alternator	65-85 amp output
Starter	1.4 kW minimum
Fuse Panel	Located under dashboard
Headlights	Sealed beam, 55/60W

WARNING! Disconnect battery ground cable before performing electrical work to prevent short circuits.

Braking System

Service procedures for hydraulic brakes, parking brake, and brake adjustment.

Brake Pad Replacement: Inspect every 12,000 miles
Brake Fluid: DOT 3 recommended
Bleeding Procedure: Start with wheel farthest from master cylinder
Parking Brake: Adjust cable tension as needed
Rotor/Drum: Resurface if scoring exceeds 0.060"

CAUTION! Test brakes at low speed after service. Never reuse brake fluid.

Suspension & Steering

Alignment specifications, component replacement, and service procedures.

Front Alignment: Camber: +0.5° to +1.5°, Caster: +2° to +3°
Toe-in: 1/8" to 1/4"
Ball Joints: Check for play every 15,000 miles
Shock Absorbers: Replace if leaking or worn
Power Steering Fluid: Use Dexron II/Mercon

Fuel System

Carburetor adjustment, fuel pump service, and fuel line maintenance.

Carburetor Adjustment: Set idle mixture for smoothest operation
Fuel Filter: Replace every 12,000 miles
Fuel Pump Pressure: 5-7 psi
Fuel Lines: Inspect for leaks and deterioration
Tank Cleaning: Remove and clean every 50,000 miles

WARNING! Work in well-ventilated area. No smoking or open flames near fuel system.

Cooling System

Radiator service, thermostat replacement, and cooling system maintenance.

Component	Specification
Radiator Cap	13-16 psi pressure
Thermostat	195°F opening temperature
Coolant	50/50 ethylene glycol mixture
Fan Belt Tension	1/2" deflection at midpoint
Water Pump	Replace if bearing noise or leakage

Troubleshooting Guide

Common problems and solutions for the 1986 Dodge W100.

Symptom	Possible Cause	Corrective Action
Engine won't start	Weak battery, faulty starter	Check battery voltage; test starter solenoid
Poor fuel economy	Dirty air filter, misadjusted carburetor	Replace air filter; adjust carburetor mixture
Overheating	Low coolant, stuck thermostat	Check coolant level; replace thermostat
Brake pulling	Stuck caliper, worn pads	Inspect calipers; replace uneven pads
Steering wander	Worn components, alignment	Check ball joints; perform alignment

Service Note: Always refer to torque specifications when reassembling components.

Safety Precautions

Important safety information for working on your Dodge W100.

Always use jack stands - never work under vehicle supported only by jack
Disconnect battery before performing electrical work
Wear safety glasses when working under vehicle
Use proper tools for each procedure
Work in well-ventilated area when working with fuels or chemicals
Keep fire extinguisher nearby when working on fuel system

EMERGENCY: For technical support contact Dodge customer service at 1-800-4ADODGE